PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) Introduction... WP 0047 Table 1. Leakage Definitions for PMCS... 0047-1 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)... WP 0048 Table 1. Preventive Maintenance Checks and Services (PMCS) for the RTCH... 0048-1 Table 2. PMCS Mandatory Replacement Parts List... 0048-8 Chapter 4 - MAINTENANCE INSTRUCTIONS
SERVICE UPON RECEIPT... WP 0049 ENGINE ASSEMBLY REPLACEMENT... WP 0050 Figure 1. Engine Removal... 0050-3 Figure 2. Engine Removal... 0050-4 Figure 3. Engine Removal... 0050-5 Figure 4. Engine Removal... 0050-5 Figure 5. Engine Removal... 0050-6 Figure 6. Engine Removal... 0050-7 Figure 7. Engine Removal... 0050-7 Figure 8. Engine Removal... 0050-8 Figure 9. Engine Removal... 0050-9 Figure 10. Engine Removal... 0050-10 Figure 11. Engine Installation... 0050-12 Figure 12. Engine Installation... 0050-13 Figure 13. Engine Installation... 0050-13 Figure 14. Engine Installation... 0050-14 Figure 15. Engine Installation... 0050-14 Figure 16. Engine Installation... 0050-15 Figure 17. Engine Installation... 0050-16 Figure 18. Engine Installation... 0050-17
Figure 19. Engine Installation... 0050-18 Figure 20. Engine Installation... 0050-19 ENGINE MOUNTS AND LIFTING BRACKETS REPLACEMENT... WP 0051 Figure 1. Lifting Brackets Removal... 0051-2 Figure 2. Lifting Brackets Installation... 0051-3 Figure 3. Front Engine Mount Installation... 0051-5 Figure 4. Rear Engine Mount Removal... 0051-7 CYLINDER HEAD REPLACEMENT... WP 0052 Figure 1. Cylinder Head Removal... 0052-1 Figure 2. Cylinder Head Removal... 0052-2 Figure 3. Cylinder Head Removal... 0052-2 Figure 4. Cylinder Head Removal... 0052-3 Figure 5. Cylinder Head Removal... 0052-3 Figure 6. Cylinder Head Removal... 0052-4 Figure 7. Cylinder Head Removal... 0052-4 Figure 8. Cylinder Head Removal... 0052-5 Figure 9. Cylinder Head Removal... 0052-5 Figure 10. Cylinder Head Removal... 0052-6 Figure 11. Cylinder Head Inspection... 0052-8 Figure 12. Cylinder Head Inspection... 0052-9 Figure 13. Cylinder Head Inspection... 0052-10 Table 1. Cylinder Head Flatness Measurements... 0052-10 Figure 14. Cylinder Head Inspection... 0052-11 Figure 15. Cylinder Head Inspection... 0052-11 Figure 16. Cylinder Head Installation... 0052-12 Figure 17. Cylinder Head Installation... 0052-13 Figure 18. Cylinder Head Installation... 0052-13
Figure 19. Cylinder Head Installation... 0052-14 Figure 20. Cylinder Head Installation... 0052-14 Figure 21. Cylinder Head Installation... 0052-15 Figure 22. Cylinder Head Installation... 0052-15 Figure 23. Cylinder Head Removal... 0052-16 Figure 24. Cylinder Head Installation... 0052-16 VIBRATION DAMPER REPLACEMENT... WP 0053 Figure 1. Vibration Damper Removal... 0053-2 Figure 2. Thickness Measure... 0053-3 Figure 3. Eccentricity Check... 0053-3 Figure 4. Wobble Check... 0053-4 Figure 5. Vibration Damper Installation... 0053-5 FLYWHEEL ASSEMBLY REPLACEMENT... WP 0054 Figure 1. Flywheel Assembly Removal... 0054-2 Figure 2. Flywheel Assembly Removal... 0054-3 Figure 3. Flywheel Assembly Removal... 0054-4 Figure 4. Flywheel Assembly Inspection... 0054-5 Figure 5. Flywheel Assembly Inspection... 0054-6 Table 1. Flywheel Face Runout... 0054-7 Figure 6. Flywheel Assembly Installation... 0054-8 Figure 7. Flywheel Assembly Installation... 0054-9 REAR MAIN OIL SEAL REPLACEMENT... WP 0055 Figure 1. Rear Main Oil Seal Removal... 0055-2 Figure 2. Wear Sleeve Removal... 0055-3 Figure 3. Wear Sleeve Removal... 0055-3 Figure 4. Wear Sleeve Removal... 0055-4 Figure 5. Wear Sleeve Removal... 0055-4
Figure 6. Rear Main Oil Seal and Thick Wear Sleeve Installation... 0055-5 Figure 7. Rear Main Oil Seal and Thick Wear Sleeve Installation... 0055-6 Figure 8. Rear Main Oil Seal and Thick Wear Sleeve Installation... 0055-6 Figure 9. Rear Main Oil Seal and Thick Wear Sleeve Installation... 0055-7 Figure 10. Rear Main Oil Seal and Thick Wear Sleeve Installation... 0055-7 Figure 11. Rear Main Oil Seal and Thick Wear Sleeve Installation... 0055-8 Figure 12. Rear Main Oil Seal and Thick Wear Sleeve Installation... 0055-9 ROCKER ARM ASSEMBLY MAINTENANCE... WP 0056 Figure 1. Push Rods and Push Tubes Removal... 0056-2 Figure 2. Key Stock Installation... 0056-2 Figure 3. Front Rocker Arm Assembly Removal... 0056-3 Figure 4. Rocker Levers Removal... 0056-4 Figure 5. Rocker Lever Disassembly... 0056-4 Figure 6. Rocker Lever Bushing Measurement... 0056-5 Figure 7. Rocker Lever Shaft Measurement... 0056-5 Figure 8. Rocker Arm Shaft Assembly... 0056-6 Figure 9. Rocker Arm Shaft Assembly... 0056-7 Figure 10. Rocker Arm Shaft Assembly... 0056-7 Figure 11. Rocker Arm Shaft Assembly... 0056-8 Figure 12. Rocker Arm Shaft Installation... 0056-8 Figure 13. Rocker Arm Shaft Installation... 0056-9 Figure 14. Rocker Arm Shaft Installation... 0056-9 Figure 15. Rocker Arm Shaft Installation... 0056-10 Figure 16. Rocker Arm Shaft Installation... 0056-10 Figure 17. Rocker Arm Shaft Installation. ... 0056-11 Figure 18. Rocker Arm Shaft Installation... 0056-11 Figure 19. Rocker Arm Shaft Installation... 0056-12
Figure 20. Rocker Arm Shaft Installation... 0056-12 Figure 21. Rocker Arm Shaft Installation... 0056-13 Figure 22. Valve Lash Check... 0056-14 Table 1. Injector and Valve Measurement Sequence... 0056-15 Figure 23. Valve Lash Check... 0056-15 Figure 24. Valve Lash Check... 0056-16 Table 2. M Series Valve Lash Recheck Limits... 0056-16 Figure 25. Injector Lash Check... 0056-17 Figure 26. Injector Lash Check... 0056-18 Table 3. M Series Injector Lash Recheck Limits... 0056-18 Figure 27. Injector Adjustment... 0056-19 Figure 28. Injector Adjustment... 0056-19 Figure 29. Valve Adjustment... 0056-20 Figure 30. Valve Adjustment... 0056-21 Figure 31. Valve Adjustment... 0056-21 Figure 32. Valve Adjustment... 0056-22 Figure 33. Valve Adjustment... 0056-22 Figure 34. Valve Adjustment... 0056-23 ROCKER ARM COVER AND GASKET REPLACEMENT... WP 0057 Figure 1. Rocker Arm Cover and Gasket Replacement... 0057-2 Figure 2. Rocker Arm Cover Tightening Sequence... 0057-3 OIL PAN REPLACEMENT... WP 0058 Figure 1. Oil Pan Removal... 0058-2 Figure 2. Oil Pan Installation... 0058-3 Figure 3. Oil Pan Installation... 0058-3 ENGINE OIL AND OIL FILTER REPLACEMENT... WP 0059 Figure 1. Drain Engine Oil... 0059-2
Figure 2. Oil Filter and Gasket... 0059-3 OIL FILTER HEAD AND OIL COOLER MAINTENANCE... WP 0060 Figure 1. Oil Filter Head and Oil Cooler Removal... 0060-2 Figure 2. Oil Filter Head and Oil Cooler Removal... 0060-2 Figure 3. Oil Filter Head and Oil Cooler Removal... 0060-3 Figure 4. Oil Filter Head and Oil Cooler Disassembly... 0060-5 Figure 5. Oil Cooler Testing... 0060-7 Figure 6. Oil Cooler Cleaning... 0060-8 Figure 7. Oil Cooler Pressure Test... 0060-9 Figure 8. Oil Filter Head Assembly... 0060-9 Figure 9. Oil Filter Head Assembly... 0060-10 Figure 10. Oil Filter Head Installation... 0060-10 Figure 11. Oil Filter Head and Oil Cooler Installation... 0060-11 Figure 12. Oil Filter Head and Oil Cooler Installation... 0060-12 Figure 13. Oil Filter Head and Oil Cooler Installation... 0060-12 ENGINE OIL DIPSTICK HOSE AND OIL FILL HOSE REPLACEMENT... WP 0061 Figure 1. Engine Oil Dipstick Replacement and Fill Hose Removal... 0061-3 Figure 2. Oil Dipstick Cover and Cylinder Block Cleaning... 0061-4 Figure 3. Engine Oil Dipstick and Fill Hoses Installation... 0061-5 OIL SAMPLING VALVES AND HOSES REPLACEMENT... WP 0062 Figure 1. Oil Sampling Valve... 0062-2 Figure 2. Engine Oil Sampling Valve Hose... 0062-3 Figure 3. Transmission Oil Sampling Valve Hose... 0062-4 Figure 4. Hydraulic System Oil Sampling Valve Hose... 0062-5 EXHAUST MANIFOLD REPLACEMENT... WP 0063 Figure 1. Exhaust Manifold Removal... 0063-1 Figure 2. Exhaust Manifold Removal... 0063-2
Figure 3. Exhaust Manifold Installation... 0063-3 Figure 4. Exhaust Manifold Installation... 0063-4 Figure 5. Exhaust Manifold Installation... 0063-5 INTAKE MANIFOLD REPLACEMENT... WP 0064 Figure 1. Intake Manifold Removal... 0064-1 Figure 2. Intake Manifold Installation... 0064-2 Figure 3. Intake Manifold Sequence... 0064-2 FRONT GEAR COVER REPLACEMENT... WP 0065 Figure 1. Front Gear Cover Removal... 0065-2 Figure 2. Front Gear Cover Removal... 0065-3 Figure 3. Front Gear Cover Removal... 0065-3 Figure 4. Front Gear Cover Installation... 0065-4 Figure 5. Front Gear Cover Installation... 0065-5 Figure 6. Front Gear Cover Installation... 0065-5 Figure 7. Front Gear Cover Installation... 0065-6 Figure 8. Front Gear Cover Tightening Sequence... 0065-7 FRONT MAIN OIL SEAL REPLACEMENT... WP 0066 Figure 1. Front Main Oil Seal Removal... 0066-1 Figure 2. Front Main Oil Seal Removal... 0066-2 Figure 3. Unitized Front Crankshaft Main Oil Seal Removal... 0066-2 Figure 4. Unitized Front Crankshaft Main Oil Seal Removal... 0066-3 Figure 5. Cleaning and Inspection... 0066-3 Figure 6. Front Unitized Crankshaft Main Oil Seal Installation... 0066-4 Figure 7. Front Unitized Crankshaft Main Oil Seal Installation... 0066-5 Figure 8. Front Unitized Crankshaft Main Oil Seal Installation... 0066-5 Figure 9. Front Unitized Crankshaft Main Oil Seal Installation... 0066-6 Figure 10. Front Unitized Crankshaft Main Oil Seal Installation... 0066-7
FUEL INJECTOR REPLACEMENT... WP 0067 Figure 1. Push Rods and Push Tubes Removal... 0067-2 Figure 2. Injector Hold-Down Clamp Removal... 0067-3 Figure 3. Injector Removal... 0067-3 Figure 4. Injector Installation... 0067-4 Figure 5. Injector Installation... 0067-5 Figure 6. Push Rods and Push Tubes Installation... 0067-5 FUEL PUMP ASSEMBLY REPLACEMENT... WP 0068 Figure 1. Fuel Pump Removal... 0068-3 FUEL HOSES, LINES, AND FITTINGS REPLACEMENT... WP 0069 Figure 1. Cooling Plate-to-Cylinder Head Fuel Line... 0069-2 Figure 2. Fuel Pump-to-Cooling Plate Fuel Line... 0069-3 Figure 3. Engine Fuel Return Line... 0069-4 Figure 4. Fuel Return Hose... 0069-5 FUEL SOLENOID SHUTOFF VALVE REPLACEMENT... WP 0070 Figure 1. Fuel Solenoid Shutoff Valve Removal... 0070-2 Figure 2. Fuel Solenoid Shutoff Valve Installation... 0070-3 Figure 3. Fuel Solenoid Shutoff Valve Installation... 0070-3 ENGINE AIR CLEANER MAINTENANCE... WP 0071 Figure 1. Engine Air Cleaner... 0071-2 Figure 2. Engine Air Cleaner Filter Elements Removal... 0071-3 Figure 3. Engine Air Cleaner Filter Elements Removal and Installation... 0071-4 Figure 4. Engine Air Cleaner Filter Elements Removal and Installation... 0071-5 ENGINE AIR INTAKE HOSES AND TUBES REPLACEMENT... WP 0072 Figure 1. Air Cleaner-to-Turbocharger Hoses and Tubes... 0072-3 Figure 2. Turbocharger-to-Charge Air Cooler Hoses and Tubes... 0072-5 Figure 3. Charger Air Cooler-to-Engine Air Intake Manifold Hoses and Tubes... 0072-7
TURBOCHARGER REPLACEMENT... WP 0073 Figure 1. Clamps Removal... 0073-2 Figure 2. Turbocharger Removal... 0073-2 Figure 3. Turbocharger Removal... 0073-3 Figure 4. Turbocharger Removal... 0073-3 Figure 5. Turbocharger Axial Clearance Check... 0073-4 Figure 6. Turbocharger Radial Bearing Clearance Check... 0073-5 Figure 7. Turbocharger Installation... 0073-6 Figure 8. Turbocharger Installation... 0073-6 Figure 9. Turbocharger Installation... 0073-7 Figure 10. Turbocharger Installation... 0073-7 FUEL TANK REPLACEMENT... WP 0074 Figure 1. Fuel Tank Removal... 0074-2 Figure 2. Fuel Tank Replacement... 0074-3 FUEL SUPPLY AND RETURN HOSES REPLACEMENT... WP 0075 Figure 1. Fuel Supply Hose... 0075-3 FUEL FILTER/WATER SEPARATOR REPLACEMENT... WP 0076 Figure 1. Fuel Pump Ball Valve... 0076-2 Figure 2. Fuel Filter... 0076-3 Figure 3. Fuel Pump Ball Valve... 0076-4 ETHER COLD START SYSTEM MAINTENANCE... WP 0077 Figure 1. Ether Canister Removal... 0077-1 Figure 2. Ether Canister Gasket... 0077-2 Figure 3. Ether Canister Installation... 0077-3 Figure 4. Cold Start Activation Solenoid Removal... 0077-4 Figure 5. Cold Start Activation Solenoid Removal... 0077-5 Figure 6. Cold Start Activation Solenoid Removal... 0077-5
Figure 7. Cold Start Activation Solenoid Removal... 0077-6 Figure 8. Cold Start Activation Solenoid Installation... 0077-7 Figure 9. Cold Start Activation Solenoid Installation... 0077-8 Figure 10. Cold Start Activation Solenoid Installation... 0077-9 THROTTLE POSITION SENSOR (ACCELERATOR PEDAL) REPLACEMENT... WP 0078 Figure 1. Throttle Position Sensor Removal - RT 240V1 and RT 240V1R... 0078-1 Figure 2. Throttle Position Sensor Removal - RT 240V1 and RT 240V1R... 0078-2 Figure 3. Throttle Position Sensor Removal - RT 240V1 and RT 240V1R... 0078-2 Figure 4. Throttle Position Sensor Removal - RT 240V2 and RT 240V3... 0078-3 Figure 5. Throttle Position Sensor Removal - RT 240V2 and RT 240V3... 0078-3 Figure 6. Throttle Position Sensor Removal - RT 240V2 and RT 240V3... 0078-4 Figure 7. Throttle Position Sensor Installation - RT 240V2 and RT 240V3... 0078-5 Figure 8. Throttle Position Sensor Installation - RT 240V2 and RT 240V3... 0078-6 Figure 9. Throttle Position Sensor Installation - RT 240V2 and RT 240V3... 0078-7 Figure 10. Throttle Position Sensor Installation - RT 240V1 and RT 240V1R... 0078-8 Figure 11. Throttle Position Sensor Installation - RT 240V1 and RT 240V1R... 0078-9 Figure 12. Throttle Position Sensor Installation - RT 240V1 and RT 240V1R... 0078-9 MUFFLER AND EXHAUST PIPE REPLACEMENT... WP 0079 Figure 1. Muffler and Exhaust Pipe Removal... 0079-3 Figure 2. Muffler and Exhaust Pipe Installation... 0079-5 DRAINING AND FILLING RADIATOR ASSEMBLY... WP 0080 Figure 1. Drain Radiator Assembly... 0080-2 Figure 2. Fill Radiator Assembly... 0080-3 Figure 3. Fill Radiator Assembly... 0080-3 Figure 4. Check Coolant Level... 0080-4 RADIATOR ASSEMBLY MAINTENANCE... WP 0081 Figure 1. Angle Plate Removal... 0081-2
Figure 2. Radiator Grille Removal... 0081-3 Figure 3. Radiator Removal... 0081-4 Figure 4. Radiator Installation... 0081-5 Figure 5. Radiator Grille Installation... 0081-6 Figure 6. Angle Plate Installation... 0081-7 COOLING SYSTEM EXPANSION TANK MAINTENANCE... WP 0082 Figure 1. Cooling System Expansion Tank Removal... 0082-2 Figure 2. Cooling System Expansion Tank Removal... 0082-3 Figure 3. Cooling System Expansion Tank Removal... 0082-4 Figure 4. Cooling System Expansion Tank Assembly and Installation... 0082-5 Figure 5. Cooling System Expansion Tank Installation... 0082-6 Figure 6. Cooling System Expansion Tank Installation... 0082-7 COOLING SYSTEM HOSES REPLACEMENT... WP 0083 Figure 1. Cab Interface Unit-to-Water Pump Hose... 0083-2 Figure 2. Cab Interface Unit-to-Engine Block Hose... 0083-3 Figure 3. Coolant Reservoir-to-Radiator Hose... 0083-4 Figure 4. Coolant Reservoir-to-Water Manifold Hose... 0083-5 Figure 5. Coolant Reservoir-to-Water Pump Hose... 0083-6 Figure 6. Transmission Oil Cooler-to-Radiator Hoses... 0083-7 Figure 7. Transmission Oil Cooler-to-Water Pump Hoses... 0083-8 Figure 8. Transmission Oil Cooler-to-Water Pump Return Hose... 0083-9 Figure 9. Transmission Oil Cooler U-Hose... 0083-10 Figure 10. Water Manifold-to-Radiator Hoses... 0083-11 RADIATOR SPLASH SHIELD REPLACEMENT... WP 0084 Figure 1. Radiator Splash Shield Installation... 0084-2 RADIATOR TOP GRATING REPLACEMENT... WP 0085 Figure 1. Radiator Top Grating Replacement... 0085-2
RADIATOR FILL COVER PLATE REPLACEMENT... WP 0086 Figure 1. Radiator Fill Cover Replacement... 0086-1 THERMOSTAT REPLACEMENT... WP 0087 Figure 1. Thermostat Removal... 0087-1 Figure 2. Thermostat Removal... 0087-2 Figure 3. Thermostat Removal and Installation... 0087-2 Figure 4. Thermostat Installation... 0087-3 WATER PUMP REPLACEMENT... WP 0088 Figure 1. Water Pump Pulley Removal... 0088-2 Figure 2. Dust and Oil Seal Removal... 0088-3 Figure 3. Water Pump Removal... 0088-3 Figure 4. Needle Bearing Inspection... 0088-4 Figure 5. Water Pump Installation... 0088-5 Figure 6. Oil and Dust Seal Installation... 0088-5 Figure 7. Water Pump Pulley Installation... 0088-6 HYDRAULIC COOLING FAN MAINTENANCE... WP 0089 Figure 1. Cooling Fan Removal... 0089-3 Figure 2. Cooling Fan Installation... 0089-5 COOLANT FILTER AND FILTER HEAD REPLACEMENT... WP 0090 Figure 1. Coolant Filter Removal... 0090-2 Figure 2. Coolant Filter Preparation... 0090-3 Figure 3. Coolant Filter Tightening... 0090-4 Figure 4. Turn Coolant Filter Head Valve ON... 0090-5 Figure 5. Coolant Filter Head Replacement... 0090-7 ALTERNATOR REPLACEMENT... WP 0091 Figure 1. Alternator Removal... 0091-1 Figure 2. Alternator Removal... 0091-2
Figure 3. Alternator Installation... 0091-3 ALTERNATOR DRIVE BELT MAINTENANCE... WP 0092 Figure 1. Alternator Drive Belt Removal... 0092-1 Figure 2. Alternator Drive Belt Installation... 0092-2 Figure 3. Alternator Drive Belt Adjustment... 0092-3 STARTER MOTOR REPLACEMENT... WP 0093 Figure 1. Starter Removal... 0093-2 Figure 2. Starter Removal... 0093-3 Figure 3. Starter Removal... 0093-3 Figure 4. Starter Installation... 0093-4 Figure 5. Starter Installation... 0093-5 INSTRUMENT PANEL SWITCHES, GAUGES, AND PANEL LAMPS REPLACEMENT... WP 0094 Figure 1. Switch/Gauge Panel Removal... 0094-2 Figure 2. Rocker Switch Removal... 0094-3 Figure 3. Switch/Gauge Panel Removal... 0094-4 Figure 4. Rotary Switch Removal... 0094-5 Figure 5. Rotary Switch Removal and Installation... 0094-7 Figure 6. Switch/Gauge Panel Installation... 0094-7 Figure 7. Rotary Switch Installation... 0094-8 Figure 8. Gauge Removal... 0094-9 Figure 9. Switch/Gauge Panel Installation... 0094-10 Figure 10. Instrument Panel Lamp Installation... 0094-11 Figure 11. Instrument Panel Lamp Installation... 0094-12 Figure 12. 12/24 Connector Removal... 0094-13 Figure 13. 12/24V Connector Installation... 0094-14 TRANSMISSION AND ACCESSORY CONTROL LEVERS REPLACEMENT... WP 0095 Figure 1. Separate Housing... 0095-1
Figure 2. Transmission and Accessory Control Levers Removal... 0095-2 Figure 3. Panel Removed... 0095-3 Figure 4. Panel Removal... 0095-3 Figure 5. Transmission and Accessory Control Levers Removal... 0095-4 Figure 6. Transmission and Accessory Control Levers Installation... 0095-5 Figure 7. Panels Installation... 0095-6 Figure 8. Panels Installation... 0095-6 Figure 9. Housing Installation... 0095-7 ECS DISPLAY SCREEN REPLACEMENT... WP 0096 Figure 1. ECS Display Screen Removal... 0096-1 Figure 2. ECS Display Screen Installation... 0096-2 Figure 3. ECS Display Screen Installation... 0096-3 TOPHANDLER JUNCTION BOX MAINTENANCE... WP 0097 Figure 1. Tophandler ECU Removal... 0097-2 Figure 2. Tophandler ECU Installation... 0097-3 Figure 3. Relay Installation... 0097-4 Figure 4. Tophandler Junction Box Removal... 0097-5 Figure 5. Tophandler Junction Box Removal... 0097-5 Figure 6. Tophandler Junction Box Removal... 0097-6 Figure 7. Tophandler Junction Box Removal... 0097-7 Figure 8. Tophandler Junction Box Removal... 0097-8 Figure 9. Tophandler Junction Box Removal... 0097-9 Figure 10. Tophandler Junction Box Replacement... 0097-10 Figure 11. Tophandler Junction Box Installation... 0097-11 Figure 12. Tophandler Junction Box Installation... 0097-12 Figure 13. Tophandler Junction Box Installation... 0097-13 Figure 14. Tophandler Junction Box Installation... 0097-13
TOPHANDLER PROXIMITY SWITCH JUNCTION BOXES REPLACEMENT... WP 0098 Figure 1. Tophandler Junction Box Cover Removal... 0098-1 Figure 2. Tophandler Junction Box Replacement... 0098-3 Figure 3. Tophandler Junction Box Cover Installation... 0098-4 ENGINE ELECTRONIC CONTROL UNIT (ECU) REPLACEMENT... WP 0099 Figure 1. ECU Replacement... 0099-3 ELECTRONIC CONTROL UNITS (ECU) REPLACEMENT... WP 0100 Figure 1. Access Panels Removal... 0100-1 Figure 2. Transmission ECU Removal... 0100-2 Figure 3. Access Panels Removal... 0100-3 Figure 4. Steering System ECU Removal... 0100-4 Figure 5. Seat Base Cover Removal... 0100-5 Figure 6. Hydraulic Servo System ECU Removal... 0100-6 Figure 7. Hydraulic Servo System ECU Installation... 0100-7 Figure 8. Seat Base Cover Installation... 0100-8 ELECTRONIC JOYSTICK ASSEMBLY REPLACEMENT... WP 0101 Figure 1. Joystick Removal... 0101-1 Figure 2. Joystick Installation... 0101-2 ELECTRONIC JOYSTICK ASSEMBLY WIRING HARNESS REPLACEMENT... WP 0102 Figure 1. Joystick Wiring Harness Removal... 0102-2 Figure 2. Joystick Wiring Harness Removal... 0102-3 Figure 3. Joystick Wiring Harness Removal... 0102-4 Figure 4. Seat Base Cover Removal... 0102-5 Figure 5. Joystick Wiring Harness Removal... 0102-5 Figure 6. Joystick Wiring Harness Removal... 0102-6 Figure 7. Joystick Wiring Harness Installation... 0102-7 Figure 8. Seat Base Cover Installation... 0102-7
Figure 9. Joystick Wiring Harness Installation... 0102-8 Figure 10. Joystick Wiring Harness Installation... 0102-9 CIRCUIT BREAKERS AND RELAYS REPLACEMENT... WP 0103 Figure 1. Access Panel Removal... 0103-1 Figure 2. Circuit Breaker/Relay Box Opening... 0103-2 Figure 3. Circuit Breaker Panel Separation... 0103-3 Figure 4. Circuit Breaker Removal... 0103-3 Figure 5. Circuit Breaker Removal... 0103-4 Figure 6. Relay Removal... 0103-5 Figure 7. Relay Replacement... 0103-6 Figure 8. Relay Connection... 0103-7 Figure 9. Circuit Breaker Connection... 0103-8 Figure 10. Circuit Breaker Installation... 0103-9 Figure 11. Circuit Breaker Panel Installation... 0103-9 Figure 12. Circuit Breaker Panel Installation... 0103-10 Figure 13. Access Panel Installation... 0103-11 Figure 14. Circuit Breaker Installation... 0103-13 Figure 15. Starter Relay Installation... 0103-14 Figure 16. Fuse Block Installation... 0103-15 TOPHANDLER PROXIMITY SWITCHES REPLACEMENT... WP 0104 Figure 1. Twistlock Proximity Switch Removal... 0104-2 Figure 2. Junction Box Cover Removal... 0104-3 Figure 3. Twistlock Proximity Switch Installation... 0104-5 Figure 4. Junction Box Cover Installation... 0104-5 Figure 5. Twistlock Proximity Switch Installation... 0104-6 Figure 6. Forklift Interlock Proximity Switch Removal... 0104-7 Figure 7. Junction Box Cover Removal... 0104-7
Figure 8. Forklift Interlock Proximity Switch Removal... 0104-8 Figure 9. Forklift Interlock Proximity Switch Removal... 0104-9 Figure 10. Junction Box Cover Installation... 0104-9 Figure 11. Twistlock Proximity Switch Installation... 0104-10 Figure 12. Spreader Beam Proximity Switch Removal... 0104-11 Figure 13. Spreader Beam Proximity Switch Removal... 0104-11 Figure 14. Spreader Beam Proximity Switch Removal... 0104-12 Figure 15. Spreader Beam Proximity Switch Installation... 0104-13 Figure 16. Spreader Beam Proximity Switch Installation... 0104-14 Figure 17. Spreader Beam Proximity Switch Installation... 0104-15 CAB POSITION PROXIMITY SWITCHES REPLACEMENT... WP 0105 Figure 1. Cab-Mounted Proximity Switch Removal... 0105-1 Figure 2. Cab-Mounted Proximity Switch Removal... 0105-2 Figure 3. Cab-Mounted Proximity Switch Replacement... 0105-3 Figure 4. Cab-Mounted Proximity Switch Installation... 0105-4 Figure 5. Cab Support-Mounted Proximity Switch Removal... 0105-5 Figure 6. Cab Support-Mounted Proximity Switch Installation... 0105-7 Figure 7. Cab-Support Mounted Proximity Switch Installation... 0105-8 SOLAR CHARGER REPLACEMENT (IF EQUIPPED)... WP 0106 Figure 1. Solar Charger Replacement... 0106-1 Figure 2. Solar Charger Replacement... 0106-2 Figure 3. Solar Charger Replacement... 0106-3 Figure 4. Solar Charger Replacement... 0106-3 Figure 5. Solar Charger Replacement... 0106-4 BOOM WIRING HARNESSES REPLACEMENT... WP 0107 Figure 1. Boom Wiring Harness Removal... 0107-1 Figure 2. Boom Wiring Harness Removal... 0107-2
Figure 3. Boom Wiring Harness Installation... 0107-3 TOPHANDLER WIRING HARNESSES REPLACEMENT... WP 0108 Figure 1. Wiring Harness A Removal... 0108-2 Figure 2. Wiring Harness A Removal... 0108-3 Figure 3. Wiring Harness A Removal... 0108-3 Figure 4. Wiring Harness A Installation... 0108-5 Figure 5. Wiring Harness A Installation... 0108-5 Figure 6. Wiring Harness B Removal... 0108-6 Figure 7. Wiring Harness B Removal... 0108-7 Figure 8. Wiring Harness B Installation... 0108-8 Figure 9. Wiring Harness B Installation... 0108-9 Figure 10. Wiring Harness C Removal... 0108-10 Figure 11. Wiring Harness C Removal... 0108-11 Figure 12. Wiring Harness C Installation... 0108-12 Figure 13. Wiring Harness C Installation... 0108-13 Figure 14. Wiring Harness D Removal... 0108-13 Figure 15. Wiring Harness D Removal... 0108-14 Figure 16. Wiring Harness D Removal... 0108-15 Figure 17. Wiring Harness D Removal... 0108-16 Figure 18. Wiring Harness D Installation... 0108-17 Figure 19. Wiring Harness D Installation... 0108-18 Figure 20. Wiring Harness D Installation... 0108-18 Figure 21. Wiring Harness E Removal... 0108-19 Figure 22. Wiring Harness E Removal... 0108-20 Figure 23. Wiring Harness E Removal... 0108-21 Figure 24. Wiring Harness E Installation... 0108-22 Figure 25. Wiring Harness E Installation... 0108-23
Figure 26. Wiring Harness E Installation... 0108-23 HEADLIGHT MAINTENANCE... WP 0109 Figure 1. Headlight Reflector Insert Removal... 0109-2 Figure 2. Headlight Bulb Replacement... 0109-3 Figure 3. Headlight Reflector Insert Installation... 0109-3 Figure 4. Light Removal and Installation... 0109-5 BACKUP LIGHT AND WORK LIGHT MAINTENANCE... WP 0110 Figure 1. Reflector Insert Removal... 0110-2 Figure 2. Bulb Replacement... 0110-3 Figure 3. Reflector Insert Installation... 0110-3 Figure 4. Light Removal and Installation... 0110-5 BLACKOUT LIGHT MAINTENANCE... WP 0111 Figure 1. Bulb/Reflector Replacement... 0111-2 Figure 2. Bulb/Reflector Replacement... 0111-3 Figure 3. Bulb/Reflector Replacement... 0111-3 Figure 4. Blackout Light Replacement... 0111-5 DIRECTIONAL BULB AND SIDE MARKER LIGHTS MAINTENANCE... WP 0112 Figure 1. Lens Removal... 0112-2 Figure 2. Bulb and LED Replacement... 0112-3 Figure 3. Lens Installation... 0112-3 Figure 4. Directional Light Replacement... 0112-5 Figure 5. Side Marker Light Cover Removal... 0112-6 Figure 6. Bulb Replacement... 0112-7 TWISTLOCK INDICATOR LIGHTS MAINTENANCE... WP 0113 Figure 1. Twistlock Indicator Light Bulb Replacement. ... 0113-2 Figure 2. Twistlock Indicator Light Bulb Replacement... 0113-3 Figure 3. Twistlock Indicator Light Removal... 0113-4
Figure 4. Twistlock Indicator Light Installation... 0113-5 Figure 5. Twistlock Infrared (IR) Light Replacement... 0113-7 CAB INTERIOR LIGHT MAINTENANCE... WP 0114 Figure 1. Cab Interior Light Bulb Removal... 0114-1 Figure 2. Cab Interior Light Bulb Installation... 0114-3 INFRARED (IR) LIGHTS REPLACEMENT... WP 0115 Figure 1. Infrared (IR) Light Removal... 0115-2 Figure 2. Infrared (IR) Light Installation... 0115-3 FORDING WATER LEVEL SENSOR REPLACEMENT... WP 0116 Figure 1. Water Level Sensor Removal... 0116-1 Figure 2. Water Level Sensor Installation... 0116-2 WHEEL TEMPERATURE SENSOR REPLACEMENT... WP 0117 Figure 1. Wheel Temperature Sensor Replacement... 0117-2 ENGINE SENSORS REPLACEMENT... WP 0118 Figure 1. Coolant Temperature Sensor Replacement... 0118-3 Figure 2. Engine Position Sensor Removal... 0118-4 Figure 3. Intake Air Temperature Sensor Replacement... 0118-5 Figure 4. Intake Manifold Pressure Sensor Replacement... 0118-6 Figure 5. Ambient Air Pressure Sensor Replacement... 0118-7 Figure 6. Ambient Air Pressure Sensor Removal (New Style)... 0118-8 Figure 7. Ambient Temperature Sensor Installation (New Style)... 0118-9 Figure 8. Oil Pressure/Temperature Sensor Replacement... 0118-10 HYDRAULIC FILTER INDICATOR SENSORS REPLACEMENT... WP 0119 Figure 1. Hydraulic Cylinder Filter Indicator Sensor Replacement... 0119-3 TRANSMISSION SENSORS REPLACEMENT... WP 0120 Figure 1. Transmission Sensors... 0120-2 Figure 2. Transmission Sensor Connector... 0120-3
Figure 3. Transmission Sensor Removal... 0120-3 Figure 4. Transmission Sensor Installation... 0120-4 Figure 5. Transmission Sensor Connector... 0120-5 BOOM ANGLE SENSOR REPLACEMENT... WP 0121 Figure 1. Boom Angle Sensor Removal... 0121-2 Figure 2. Boom Angle Sensor Removal... 0121-3 Figure 3. Boom Angle Sensor Removal... 0121-4 Figure 4. Boom Angle Sensor Installation... 0121-5 BOOM EXTENSION SENSOR REPLACEMENT... WP 0122 Figure 1. Boom Extension Sensor Removal... 0122-1 Figure 2. Boom Extension Sensor Removal... 0122-2 Figure 3. Boom Extension Sensor Removal... 0122-3 Figure 4. Boom Extension Sensor Installation... 0122-4 TOPHANDLER ANGLE SENSOR REPLACEMENT... WP 0123 Figure 1. Tophandler Angle Sensor Removal... 0123-2 Figure 2. Tophandler Angle Sensor Removal... 0123-3 Figure 3. Tophandler Angle Sensor Removal... 0123-4 Figure 4. Tophandler Angle Sensor Removal... 0123-5 Figure 5. Tophandler Angle Sensor Installation... 0123-6 Figure 6. Tophandler Angle Sensor Installation... 0123-7 Figure 7. Tophandler Angle Sensor Installation... 0123-8 Figure 8. Tophandler Angle Sensor Installation... 0123-9 HYDRAULIC RESERVOIR AND LIFT CYLINDER SENSORS REPLACEMENT... WP 0124 Figure 1. Temperature Sensor Replacement... 0124-2 Figure 2. Pressure Sensor Replacement... 0124-3 Figure 3. Lift Cylinder Sensor Replacement... 0124-4 STEERING SYSTEM WHEEL SENSOR REPLACEMENT... WP 0125
Figure 1. Steering System Wheel Sensor Removal... 0125-2 Figure 2. Steering System Wheel Sensor Removal... 0125-3 Figure 3. Steering System Wheel Sensor Removal... 0125-4 Figure 4. Steering System Wheel Sensor Installation... 0125-5 Table 1. Rear Junction Box X167 Wire Connections... 0125-6 Table 2. Front Junction Box X192 Wire Connections... 0125-6 Figure 5. Steering System Wheel Sensor Installation... 0125-7 Figure 6. Steering System Wheel Sensor Installation... 0125-8 SEAT WARNING BUZZER REPLACEMENT... WP 0126 Figure 1. Seat Warning Buzzer Replacement... 0126-1 Figure 2. Seat Warning Buzzer Replacement... 0126-2 Figure 3. Seat Warning Buzzer Replacement... 0126-3 Figure 4. Seat Warning Buzzer Replacement... 0126-4 ELECTRIC HORN REPLACEMENT... WP 0127 Figure 1. Electric Horn Replacement... 0127-2 BATTERY MAINTENANCE... WP 0128 Figure 1. Battery Replacement... 0128-2 Figure 2. Battery Service... 0128-3 Figure 3. Battery Installation... 0128-4 BATTERY CABLES REPLACEMENT... WP 0129 Figure 1. Battery Cables Replacement... 0129-2 Figure 2. Solar Charger Disconnect... 0129-2 Figure 3. Battery Cables Replacement... 0129-3 Figure 4. Battery Cables Replacement... 0129-4 Figure 5. Solar Charger Connection... 0129-5 Figure 6. Battery Cables Replacement... 0129-5 MASTER BATTERY SWITCH REPLACEMENT... WP 0130
Figure 1. Master Battery Switch Replacement... 0130-1 Figure 2. Master Battery Switch Replacement... 0130-2 Figure 3. Master Battery Switch Replacement... 0130-3 AMBIENT TEMPERATURE SENSOR REPLACEMENT... WP 0131 Figure 1. Ambient Temperature Sensor Removal... 0131-2 Figure 2. Ambient Temperature Sensor Installation... 0131-3 FUEL LEVEL SENDING UNIT REPLACEMENT... WP 0132 Figure 1. Fuel Level Sending Unit Connector Removal... 0132-1 Figure 2. Fuel Level Sending Unit Removal... 0132-2